Optimizing Production Efficiency and Workforce Utilization in Edible Oil Tin Manufacturing Industry
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This case study delves into the strategic initiatives undertaken by a prominent edible oil tin manufacturer and supplier to enhance its operational efficiency and adaptability in a competitive market. The company's vision of offering a diverse product portfolio tailored to varying customer requirements serves as the driving force behind its transformation journey. Through meticulous approaches such as time studies, work distribution optimization, and value stream analysis, the company aimed to streamline its indirect operations.
Key Points
- Study of assembly line for work standardization.
- Line balancing for 2.4 & 3.0 sec cycle time, Throughput 25 & 20 Tins / min respectively.
- Dynamic summary for Production planning of multiple making & filling line with varying demand.
Client's Challenge
- Work Content Estimation on installed capacity.
- Work distribution with optimum utilization of manpower.
- Identifying constraints in Value streamline.
PMI's Approach
- Identification of Project scope.
- Data collection & Video Shooting of various Processes.
- Preparation of Process Flow & Schematic Layout.
- Elemental detail preparation using PMTS technique (MODAPTS®)
- Work content estimation & Analysis.
- Manpower calculation.
- Work distribution with Man machine chart.
- Improvements & Suggestions (Waste removal, Layout, LCA).
- Dashboard based on fluctuation in demand
Data Collection:
- Identification of Project scope.
- Data collection & Video Shooting of various Processes
- Collect older Process Flow & Schematic Layout.
- Production data and shift time available data from client.
Data Analysis:
- Improvements & Suggestions (Waste removal, Layout, LCA).
- Dashboard based on fluctuation in demand
- Interaction with client to understand documents and processes
Results & Conclusion
After doing analysis and evaluation following results were obtained –
- Optimum work distribution with enhancement in Manpower Utilisation.
- Dashboard for production planning, resource calculation of multiple line considering varying demand.
Dashboard for Production Planning & Resource Calculation
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